Safety Helmet Molding Case Study: Double Output with Huarong

For manufacturers specializing in high-end safety helmets, standing out in a competitive market means overcoming three core challenges:

• Maintaining Quality Consistency: Safety helmet shells require exceptionally uniform wall thickness, free from defects such as shrinkage or warpage. On conventional machines, fluctuations in hydraulic pressure and mold temperature during long production runs can lead to common injection molding defects, such as short shots, silver streaks, and flash, which compromise the product's ability to consistently pass high-level safety certifications.
• Production Efficiency Bottlenecks: In the manufacturing workflow, long cooling times are the single biggest bottleneck for production capacity. When faced with urgent or high-volume overseas orders, a traditional linear production process with its long average cycle time often fails to respond promptly, leading to delivery delays and lost business opportunities.
• Rising Hidden Costs: The cost of precision molds is exceptionally high. If a machine lacks sufficient positioning accuracy, it not only accelerates mold wear but also increases the frequency of downtime for calibration and maintenance. These factors translate directly into hidden costs that erode profitability.

After a thorough analysis of the product's structure and production cycle, the client implemented a solution using three Huarong machines, each tailored for specific molding requirements:

• Two-Shot Injection Molding Machine (1 unit): Responsible for the single-step molding of the safety helmet shell and its integrated red rim.
• Servo Injection Molding Machines (2 units): Used to produce the transparent plastic headband (the internal support structure) and safety buckles.

Huarong's HDC series two-shot injection molding machine features two independent injection units. This allows for the simultaneous injection of different materials or colors within the same mold, enabling the successful molding of both the helmet shell and its rim in a single process. This innovative approach eliminates the need for secondary assembly and gluing, not only improving the bond strength but also enhancing the product's visual consistency.

Furthermore, the HDC machine features Huarong's proprietary patented turntable module (Patent No.: M391464), which includes a triple-protection mechanism (mechanical, safety, and hydraulic). This ensures precise positioning without sagging and stable operation during rotation, effectively protecting both the mold and the operator.

This solution empowered the client to achieve:

• One-shot molding of a dual-material helmet shell.
• Elimination of defects associated with manual gluing and secondary processing.
• Improved cycle time efficiency and product consistency.
• Reduced long-term costs for mold maintenance and energy consumption, fully leveraging the cycle time advantages of a dual-station setup.

Related Product: Double Injection Molding Machine – HDC Series

To meet the high-volume production demands for accessories such as the helmet's inner headband and safety buckles, the client selected Huarong's HR320FC and HR150SFC servo-hydraulic injection molding machines. These machines were selected to satisfy the high standards for dimensional consistency, cosmetic quality, and production efficiency.

The HRS/HRFC series utilizes a high-response servo system combined with proportional valves and high-resolution encoders. This provides real-time, closed-loop control over injection pressure and speed, resulting in stable filling and highly repeatable shots with minimal deviation. Compared to traditional hydraulic machines, this system delivers energy savings of up to 70%. The stable oil temperature further enhances cooling efficiency and system response speed, effectively resolving common accessory manufacturing issues such as dimensional inaccuracies, short shots, and flash.

With these two servo machines, the client successfully established:

• A stable molding process for plastic headbands and buckles.
• Reduced cycle times, leading to higher output.
• Lower defect rates and less material wastage.
• Increased mold lifespan and production consistency, making it ideal for high-volume manufacturing of safety-critical plastic components.

Related Product: Servo Injection Molding Machines – HRS & HRFC Series

The servo systems in this case study delivered significant electricity savings for the client, marking a major step towards green manufacturing and sustainability. However, Huarong's energy-saving technology extends even further.

If you are looking to optimize your factory's energy efficiency, we also offer these advanced options:

• Direct Drive Material Storage Motor (Patent No.: M654645): This enhances power transmission efficiency and supports simultaneous movements (dosing during cooling/mold-opening) to effectively shorten cycle times.
• Microcellular Foam Injection Molding Technology (Patent No.: M659181): By utilizing a supercritical gas for foaming, this technology can reduce product weight, material consumption, and clamping force, thereby comprehensively improving both energy efficiency and quality stability.

These technologies are already widely used in the automotive, electronics, home appliance, medical, and consumer goods industries. They not only significantly reduce production costs but also help companies achieve ESG carbon reduction goals, smart factory upgrades, and long-term sustainable operations.

Related Article: Direct Drive Material Storage Motor Application Wins 2025 Taiwan Excellence Award 

Further Reading: Microcellular Foaming – Revolutionizing Lightweight Injection Molding

This success story proves that choosing Huarong is more than just acquiring high-performance equipment; it's a strategic investment in your company's future competitiveness. In summary, Huarong's solution brings four irreplaceable advantages to your production line:

Huarong's two-shot turntable (HDC) design transforms the unproductive "cooling wait time" of traditional processes into a highly efficient, simultaneous workflow. This maximizes cycle time reduction, helping you confidently manage market rushes and large-volume orders.

From the precise two-color bonding of the HDC machine to the stable holding pressure of the servo system, we ensure every single product shot exhibits superior consistency. This enables your yield rate to easily exceed 99% and confidently meet the most stringent international safety standards.

We understand that molds are your core assets. Huarong's patented turntable protection mechanism (M391464) and precise clamping control effectively prevent mold damage, significantly extending its service life while drastically reducing maintenance costs and downtime risks.

The high-efficiency servo system, standard across our entire series, combined with advanced options like the Direct Drive Material Storage Motor (M654645), not only saves you considerable energy costs but also helps your business achieve its ESG sustainability goals, enhancing brand value and market competitiveness.

Is your production line also facing challenges with efficiency, quality, or cost? A small change today can become the key to outperforming your competition tomorrow.

The team at Huarong does more than just sell equipment—we are eager to become your technical partner. We will listen to your specific needs, gain a deep understanding of your products and processes, and tailor a solution that gives you the ultimate competitive edge.

Don't hesitate. Real change begins with the first technical consultation.

• Group Name: Huarong Group
• Brand: Huarong, Yuhdak, Nanrong
• Service Offerings: Injection Molding Machine, Vertical Injection Molding Machine, Injection Molding Automation
• Tel: +886-6-7956777
• Address: No.21-6, Zhongzhou, Chin An Vil., Xigang Dist.., Tainan City 72351, Taiwan
• Official Website: https://www.huarong.com.tw/